Wall construction



Jan. 16, 1934. M BQYLAND 1,943,285

RUCTION Filed Oct, 3, 1932 3 Shams-Sheet l NNNNN OR P ATTORNEY 16, BOYLAND I 1,943,285

WALL CONSTRUCTION Filed Oct. 3, 1932 3 Sheets-Sheet 2 iii- INVENTOR flank M Baylama! ATTORNEY Jan. 16, 1934. BQYLAND 1,943,285

WALL CONSTRUCTION Filed Oct. 3, 1932 3 Sheets-Sheet 3 INVENTOR flank/[.Bqyland ATTORN EY Patented Jan. 16, 1934 UNITED STATES PATENT OFFlCE 18 Claims.

The object of my invention is to utilize slabs or panels of plasterboard, celotex, or the like, for cheaply installing walls, particularly partition walls. The slabs or panels may be relatively large area rectangles, so that two of them can be arranged to reach from the floor to the ceiling of an ordinary room; and the width may be greater or less than the height, as for instance, 5 or 6 feet by 6 or 7 feet. The main feature is a series of metallic studs of special form extending from the bottom to the top of the room, and having longitudinal flanges projecting laterally, parallel with the wall, against which flanges the edges of the panel board are clamped by special keys passing through slots in the studs and rotated into clamping position. Preferably also, the stud also has front and rear stiffening flanges that fit the side edges of the panels. The adjacent top and bottom edges of the panels may be tongued and grooved, but I prefer to interpose a horizontal channel bar, so that the panels are framed in and stiffened horizontally as well as vertically.

My novel stud key and panel bar construction may be used in combination with panel boards of varying thicknesses, for the ready and cheap installation of various kinds of walls. For instance, where the wall is to be heavily plastered, the panel board may be relatively thin, say inch for a 2 inch wall, the thickness of the plaster being suficient to completely embed the panels, studs and keys, leaving a smooth outer plaster surface. Or the plasterboard itself may be thick enough to constitute the main surface of the wall, in which case the edges of the board are recessed so as to leave a central border of suitable thickness for clamping by the key and stud, the wall being completed by merely filling the recess flush with gypsum. In the latter case, thick composition board may have vertical and horizontal wires embedded in it with the loose ends projecting into the recess, in position for interengagement with the ends of corresponding wires of the adjacent panel, so that when the recess is filled the wires constitute substantial metallic reenforcement, in addition to the studs and channel bar.

The above and other features of my invention will be more evident from the following description in connection with the accompanying drawings, in which Fig. l is a perspective view showing one form of stud embodying novel features of my invention;

Fig. 2 is a section on the line 2 2, Fig. 1;

Fig. 3 is a similar view showing a modified form of stud;

Fig. 4 is a perspective view of one form'ofkey bar for use in combination with the studs shown in Figs. 1, 2 and 3; r

Fig. 5 is a fragmentary detail showing a characteristic horizontal section through a stud bar of a plaster wall made in accordance with my present invention, the said bar section corresponding to the line 55, Fig. 1;

Fig. 6 is a characteristic section like Fig. 4 except taken on a line corresponding to 22, Fig. 1, the key which cooperates with this part of the stud being shown in elevation;

Fig. '7 is a characteristic horizontal section showing the stud and key utilized in a double wall construction; and

Fig. 8 is a horizontal section of the stud and locking key like that shown in Fig. 6, where the panels are the full thickness of the walls but have their edges recessed to fit a standard size studand clamp, with the clamp housed wholly within the recess; and

Fig. 9 is a front elevation of a construction like that shown in Fig. 8, with parts broken away to show the horizontal channel bar and joint between upper and lower panels.

A desirable standardized form and size of stud is shown in Fig. 1 and, on a larger scale in Fig. 2, as consisting of long metal strips bent or folded lengthwise so as to have a symmetrical cross section comprising the central portion 1 having therethrough a long slot 2 through which the head of the key may be inserted; inwardly projecting flanges 8, 3, preferably formed as a U- bend, the width of which may be say 1/16 inch; similar rearwardly extending flanges 4, 4 and lateral flanges 5, 5 parallel with the plane of the wall.

In addition to the key slot 2, I prefer to provide slots 6, 6, in each of the flanges 3, 3, and 4, 4, and also in the lateral flanges 5, 5. These slots 6 have the important function of keying slots filled by mortar when the stud is embedded therein, and they also facilitate filling the U spaces in flanges 4, 4 with mortar; all with the result of forming a construction in which the stud and the plaster constitute mutually reenforced elements. As shown in Fig. 3, substantially the same flanges and slots may be embodied in a rolled metal bar, the corresponding elements being indicated by corresponding numerals, with an added exponent.

Fig. 4 shows a key suitable for clamping the panels to the stud. In this case, it consists of a cylindrical bar '7 split at one end and bent outwardly to form blocking lugs 8, 8, the cylindrical rear surfaces of which constitute cams, and the cam effect may be increased by bending said projections 8, 8, at angles slightly less than 90 to the shank 7.

The other end of shank 7 is also split and the oppositely bent portions are curved toward the end so as to form smoothly around bearing surfaces 9, 9, for engagement with the panel board. Preferably the metal has sufficient resilience to apply a substantial spring-clamping pressure on the board.

As shown in Figs. 5 and 6, the flat edge faces of the panel boards 10, 10, are placed against faces of flanges 5, 5, preferably the front faces, the lateral edges of the panels confronting the transverse stifiening ribs 3, 3, or 4, 4, as the case may be. The lugs, 8, 8, of the key are turned parallel with the length of the slots 2 and inserted therethrough, the key then being turned at right angles so that the camming rear faces of the lugs 8 wedge upward and bear squarely upon the tips of ribs 4, 4. The proportions of the parts are such with reference to the thickness of panels 10 and the width of ribs 4, 4, that the panel engaging surfaces 9, 9, are resiliently pressed against the panel boards.

As indicated by dotted lines in Fig. 5, a channel bar 11 extends horizontally between adjacent edges of the upper and lower panel and the bottom of said channel bar is preferably cut away between lines 12, 12, to form a relatively long slot through which the stud passes vertically, the length of said slot being sufficient to afford wide latitude for desired spacing of the several studs in the single horizontal channel bar. The solid bottom also permits the entry of the mortar, gypsum or other plastic, which serves to bind the parts in place.

When the above structure, that is the horizontal channel bar, vertical studs therethrough, panels clamped against the studs, etc., are in position, all of said parts may be completely embedded in and covered to a suitable depth by a mortar or other plastic 13, which is applied to both surfaces.

As shown in Fig. '7, a double wall construction may be had by utilizing the slots 6, 6, in flanges 3, 3, as key seats for a spacing bar 14 which in this case is a cylindrical bar like 7, but of greater diameter, split at each end to form oppositely camming lugs 15, 15 and 16, 16. It will be under.- stood that this spacing member 14 is inserted through a slot 2, which is between two of the slots occupied by the panel clamping keys described in connection with Fig. 6. In Fig. '7, the object is to have a double wall with dead air space for insulation, concealing pipes, etc., or wires. Consequently, only the outer faces of panels 10, 10 and the outer ends 9, 9 of the locking key are embedded in the plaster.

In Figs. 8 and 9, I have shown a construction in which thick panel boards, say 1 inch to 2 inches in thickness constitute most of the area of the wall, the plaster being applied only to the studs and locking keys. The thick panel 20 has its vertical side edges formed with a front recess 21 and a rear recess 22, so as to form aaclamping edge 23 which may be of the same thickness as the thin plasterboard 10 shown in Figs. 5, 6 and '7; and it must be of substantially that thickness, if, as preferred, studs and locking keys of the same standard dimensions are employed.

In view of the clear description of the studs and locking keys, and their relation to the panel board, it is only necessary to add with reference to Fig. 8, that the depth of recesses 21 and 22 is sufficient so that when they are filled with plastic gypsum 13a, as indicated, the studs and also both ends of the clamping key are completely buried beneath the surface, when said surface is finished oif flush with the surfaces of plasterboard 20.

As shown in Fig. 8, the plasterboard is thick .enough to permit of embedding wires in the panels, the wires 26 extending vertically and wires 27 extending horizontally. The horizontal wires 2'7 have free ends extending into recess 22 which may be stretched tightly around the studs and twisted together as more or less crudely indicated in dotted lines at 29, 30, Fig. 8, for example.

In this type of wall, the horizontal bottom edge of an upper panel and upper edge of the lower panel may be stayed and rendered structurally integral by use of a channel bar employed as a spacer as shown in Fig. 9. In said figure, a channel bar 11a, somewhat like the one indicated in dotted lines at 11 in Fig. 5, has its bottoms slotted as at 12a to accommodate the vertical studs and, between said studs the bottom is cut through, as at 12b, 12b, to form tongues 12c projecting upwardly and 12d projecting downwardly. Tongues 12d engage the upper edge of the lower panel 20 and tongues 12c engage the lower edge of the upper panel 20, thereby spacing said panels apart, with the body portion of the channel iron midway between them. This affords ample space for securing together the projecting ends of vertical reenforcing wires 26, 26, as at 2611. It also affords ample space for packing in the gypsum composition which embeds, and is reenforced by the channel bar 11a and tongues 12a, 12d. The composition is keyed to the panels by having it filled into grooves 40, 40, in the adjacent horizontal edges of the body portion of the respective upper and lower panels 20.

This affords a rigid reenforcement and binder between said adjacent edges of the upper and lower panels.

Fig. 8 also shows the studs are adapted for use in making strong corners where two walls join one another. At the upper left-hand corner, two of the studs of standard construction are secured together by bolts 41, bolted through slots 6 in flange 4 of one stud and flange 5 of an adjacent stud. In this case, the key for securing the respective plasterboards must have one handle sawed off, the other handle 9 being used for insertion and turning of the key to clamp the plasterboard to the studs.

Where a partition wall is required to run into a continuous wall, the thin edge 23 of the plasterboard may be slotted as indicated at 23a, at suitable points for straddling the handles 9 of each locking key.

In this connection, it is obvious that the locking keys for each panel board may be spaced as closely together as desired, say, 6 inches more or less.

Preferably, the thick panel boards used in Figs. 8 and 9 are of relatively small area on account of their great weight and the desirability for strong reenforcements. In certain cases, slabs 48 inches by 24 inches, more or less, may be employed. This appears to be a suitable size for slabs 1%. inches thick.

While I have described quite specifically certain desirable embodiments of my invention, it will be obvious that the proportions, sizing and spacing of the parts of the slots and the keys, as well as the types and thicknesses of walls, may be'varied within wide limits.

I claim:

1. In a panel board wall construction, a stud formed with a central body portion having longitudinal openings at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; together with a series of tension devices extending through said body openings and detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges.

2. In a panel board wall construction, a stud formed with a central body portion having longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; together with means detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping key having an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head with a handle bar in clamping relation to said panel boards.

3. In a panel board wall construction, a stud formed with a central body portion having longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; together with means detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping key having an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head With a handle bar in clamping relation to said panel boards; the length of the key being such that when rotated to transverse looking position, the head clamps the rearwardly extending flanges of said stud, and the handle clamps the panel boards against said lateral flanges.

4. In a panel board Wall construction, a stud formed with a central body portion having longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; together with means detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping key having an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head with a handle bar in clamping relation to said panel boards, the length of the key being such that when rotated to transverse locking position, the head clamps the rearwardly extending flanges of said stud, and the handle clamps the panel boards against said lateral flanges, the head of said key being formed for camming engagement with the rear flanges and said handle being slightly elastic, for the purpose described.

5. In a panel board wall construction, a stud formed with a central body portion having longitudinal openings at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flan es between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges that are parallel with the plane of the wall and both said pairs of front and rear flanges, together with means detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges.

6. In a panel board wall construction, a stud formed with a central body portion having lonitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel With the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges, together with means detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping key having an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head with a handle bar in clamping relation to said panel boards.

'7. In a panel board wall construction, a stud formed with a central body portion having longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges, together with means detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping key having an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head with a handle bar in clamping relation to said panel boards; the length of the key being such that when rotated to transverse looking position, the head clamps the rearwardly extending flanges of said stud, and the handle clamps the panel boards against said lateral flanges.

8. In a panel board wall construction, a stud formed with a central body portion having longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges, together with means detachably engaging the studs and clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping key having an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head with a handle bar in clamping relation to said panel boards the length of the key being such that when rotated to transverse locking position, the head clamps the rearwardly extending flanges of said stud, and the handle clamps the panel boards against said lateral flanges, the head of said key being formed for camming engagement With the rear flanges and said handle being slightly elastic, for the purpose described.

9. In a panel board wall construction, a series of vertical studs spaced apart the width of a panel and each formed a central body portion having longitudinal openings at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges, together with a series of tension devices extending through said body openings and detachably clamping the horizontal rows of panels, each stud being formed border portions of the panel boards against the faces of said lateral flanges;

10. In a panel board wall construction, a series of vertical studs spaced apart the width of a panel and each formed with a central body portion having longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges, together with means detachably clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping Key havin an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head with a handle bar in clamping relation to said panel boards.

11. In a panel board wall construction, a series of vertical studs spaced apart the width of a panel and each formed with a central body portion havin longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges, together with means detachably clamping the border portions of the panel boards against the faces of said lateral flanges; said means including a clamping key having an elongated head adapted to be inserted through said longitudinal body slot, a shank connecting the head with a handle bar in clamping relation to said panel boards,

the length of the key being such that when rotated to transverse locking position, the head clamps the rearwardly extending flanges of said panel and each formed with a central body portion having longitudinal slots at suitable intervals therein and longitudinal flanges extending laterally, parallel with the plane of the wall, and with pairs of front and rear flanges between said body portion and said lateral flanges; said stud being formed of a single strip of sheet metal, angularly bent so as to form said flanges, together with a key detachably clamping the border portions of the panel boards against the faces of said lateral flanges, the head or" said key being formed for camming engagement with the rear flanges and said handle being slightly elastic, for the purpose described.

13. A wall construction including vertical studs for engaging the vertical borders of vertical and horizontal rows of panels, each stud being formed with longitudinal flanges extending laterally, parallel with th plane of the wall, and with frontto-rear stiffening flanges; together with means detachably engaging the studs and clamping the vertical borders of the panel boards against the faces of said lateral flanges; in combination with horizontal channel bars between adjacent horizontal edges of panels in the same vertical row; said studs, clamping means and channel bars being embedded in plaster.

14. A wall construction including vertical studs for engaging the vertical borders of vertical and with longitudinal flanges extending laterally, parallel with the plane of the wall, and with frontto-rear stiffening flanges; together with means detachably engaging the studs and clamping the vertical borders of the panel boards against the faces of said lateral flanges; in combination with horizontal channel bars between adjacent horizontal edges of panels in the same vertical row; said flanges being slotted and said studs, clamping means and channel bars being embedded in plaster.

15. A panel board wall construction, including vertical studs spaced apart, the width of a panel, each stud being formed with a central body portion, longitudinal flanges projecting laterally, parallel with the face of the wall, and a plurality of longitudinal stiffening flanges projecting at right angles to the wall; together with means detachably engaging the studs and clamping the vertical borders of the panel boards against the faces of said lateral flanges, all of said parts being embedded in plaster which forms a wall surface.

16. A panel board wall construction, including vertical studs spaced apart, the width of a panel, each stud being formed with a central body portion, longitudinal flanges projecting laterally, parallel with the face of the wall, and a plurality of longitudinal stiffening flanges projecting at right angles to the wall to provide edge abutments for the panel boards; together with a series of tension devices detachably engaging said body portion of the studs and clamping the vertical borders of the panel boards against the faces of said lateral flanges, said studs and clamping means being embedded in plaster which forms a wall surface.

17. A panel board wall construction, including vertical studs spaced apart, the width of a panel, each stud being'formed with a central body portion, longitudinal flanges projecting laterally, parallel with the face of the wall, and a plurality of longitudinal stiffening flanges projecting at right angles to the wall to provide edge abutments for the panel boards; together with a series of tension devices detachably engaging said body portion of the studs and clamping the vertical borders of the panel boards against the faces of said lateral flanges; said flanges being slotted and said studs, clamping means and channel bars being embedded in plaster.

18. A wall construction including vertical studs for engaging the vertical borders of vertical and horizontal rows of panels, each stud being formed with longitudinal flanges extending laterally, parallel with the plane of the wall, and with frontto-rear stiffening flanges; together with means detachably engaging the studs and clamping the vertical borders of the panel boards against the faces of said lateral flanges; in combination with horizontal channel bars between adjacent horizontal edges of panels in the same vertical row; said panels having body portions substantially thicker than the front to rear dimensions of the studs and clamps, vertical border portions reoessed to contain and engage said parts and adjacent horizontal edges that are grooved, said recesses and grooves being filled with, and said studs, clamping means, channel bars embedded in plaster.

FRANK M. BOYLAND. 

